Automated storage and retrieval system with integral secured personnel access zones and remote rover shutdown

• US 10,359,777 B2
• Filed: 10/02/2018
• Issued: 07/23/2019
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Symbotic, Llc
• Original Assignee: Symbotic, Llc
• Inventors: Dorval, Rick K., Comins, Todd
• Primary Examiner(s): Logan, Kyle O
• Application Number:
  US16/150,085
• Publication Number:
  US 20190033852A1
• Time in Patent Office: 294 Days
• CPC Class Codes: B65G 2207/40 Safety features of loads, equipment or persons
• CPC Class Codes: G05D 1/00 Control of position, course, altitude or attitude of land, water, air or space vehicles, e.g. using automatic pilots drive control systems specially adapted for autonomous road vehicles B60W60/00
• CPC Class Codes: G05D 1/0297 by controlling means in a control room

Abstract

A transportation system having a transportation space including destinations distributed in the transportation space, multiple independent automated vehicles configured for free roving through the transportation space to and between the destinations so that the vehicles are dynamically distributed through the transportation space, a control system communicably connected via a remote communication link to each of the vehicles and having a system controller that addresses each vehicle to different destinations, and the control system having a vehicle accountant controller separate and distinct from the system controller and configured to independently register a dynamic location of at least one of the vehicles, selected from the multiple vehicles in the transportation space, and command shutdown, via the remote communication link, to only the selected at least one vehicle at the registered location if the registered location corresponds to a predetermined location.

Claims

1. A method comprising:

providing a transportation space including destinations distributed in the transportation space;

providing multiple independent automated vehicles configured for free roving through the transportation space to and between the destinations so that the vehicles are dynamically distributed through the transportation space;

providing a control system communicably connected via a remote communication link to each of the vehicles and having a system controller that addresses each vehicle to different destinations and a vehicle accountant controller separate and distinct from the system controller and connected via the remote communication link to each of the multiple independent automated vehicles;

independently and automatically registering, with the vehicle accountant controller of the control system, a dynamic location of each of the at least one of the multiple independent automated vehicles, selected from the multiple independent automated vehicles in the transportation space;

commanding shutdown, via the remote communication link between the vehicle accountant controller and each of the multiple independent automated vehicles, to only the selected at least one of the multiple independent automated vehicles at the registered location if the registered location corresponds to a predetermined location; and

effecting, with the control system, a human access lockout to at least a portion of the transportation space depending on the commanded shutdown of the selected at least one of the multiple independent automated vehicles.

2. The method of claim 1, further comprising effecting independent navigation through the transportation space of each of the multiple independent automated vehicles.

3. The method of claim 1, wherein the predetermined location defines a zone in the transportation space segregated from another zone in the transportation space.

4. The method of claim 1, wherein the transportation space is three dimensional space with stacked levels, each level having at least one open deck and aisles for the multiple independent automated vehicles to traverse, the aisles communicating with the deck so that the multiple independent automated vehicles enter the aisles from the deck.

5. The method of claim 1, wherein the remote communication link is common to both the system controller and the vehicle accountant controller.

6. The method of claim 1, wherein the remote communication link is a wireless link.

7. The method of claim 1, wherein the vehicle accountant controller is configured to use a black channel communication protocol over the remote communication link to command shutdown of the at least one of the multiple independent automated vehicles.

8. The method of claim 1, further comprising opening, with the vehicle accountant controller, communication between the accountant controller and the selected at least one of the multiple independent automated vehicles over the remote communication link for transmitting the shutdown command to the selected at least one of the multiple independent automated vehicles.

9. The method of claim 1, further comprising effecting, with the communication protocol of the commanded shutdown, a secure and verified command on receipt by the selected at least one vehicle.

10. The method of claim 1, further comprising effecting secure and verified shutdown of the selected at least one of the multiple independent automated vehicles upon receipt of and in response to the commanded shutdown, and confirming shutdown to the vehicle accountant controller.

11. The method of claim 1, wherein a communication state between the vehicle accountant controller and each of the multiple independent automated vehicles is normally closed and communication is opened by the vehicle accountant controller to the selected at least one of the multiple independent automated vehicles in connection and substantially coincident with the vehicle accountant controller commanding shutdown to the selected at least one of the multiple independent automated vehicles.

12. The method of claim 11, further comprising closing the communication state upon confirmation of shutdown of the selected at least one of the multiple independent automated vehicles by the vehicle accountant controller.

13. The method of claim 1, wherein a communication state between the vehicle accountant controller and each of the multiple independent automated vehicles is normally closed and communication is opened by the vehicle accountant controller to the selected at least one of the multiple independent automated vehicles in connection and substantially coincident with the vehicle accountant controller commanding activation of the selected at least one of the multiple independent automated vehicles previously shutdown.

14. A method comprising:

providing a transportation space including destinations distributed in the transportation space;

providing multiple independent automated vehicles configured for free roving through the transportation space to and between the destinations so that the multiple independent automated vehicles are dynamically distributed through the transportation space;

providing a control system communicably connected via a remote communication link to each of the multiple independent automated vehicles and having a system controller that addresses each of the multiple independent automated vehicles to different destinations and a vehicle accountant controller separate and distinct from the system controller, the vehicle accountant controller being connected via the remote communication link to each of the multiple independent automated vehicles;

independently and automatically registering, with the vehicle accountant controller, a dynamic location of each of the at least one of the multiple independent automated vehicles, selected from the multiple independent automated vehicles in the transportation space; and

commanding shutdown, via the remote communication link between the vehicle accountant controller and each of the multiple independent automated vehicles, to only the selected at least one of the multiple independent automated vehicles at the registered location if the registered location corresponds to a predetermined location;

wherein the commanded shutdown as generated for communication by the vehicle accountant controller and received by the selected at least one of the multiple independent automated vehicles, and the system of the selected at least one of the multiple independent automated vehicles responsive to the commanded shutdown define a secure and verified remote shutdown system in compliance with IEC61508, SIL 3 category criteria.

15. A method comprises:

providing a transportation space including destinations distributed in the transportation space;

providing multiple independent automated vehicles configured for free roving through the transportation space to and between the destinations so that the vehicles are dynamically distributed through the transportation space; and

providing a control system communicably connected via a remote communication link to each of the multiple independent automated vehicles and having a system controller that addresses each of the multiple independent automated vehicles to different destinations and a vehicle accountant controller separate and distinct from the system controller, the vehicle accountant controller being connected via the remote communication link to each of the multiple independent automated vehicles;

independently and automatically registering, with the vehicle accountant controller, a dynamic location of each of at least one of the multiple independent automated vehicles in response to being provided a predetermined location in the transport space and corresponding to the predetermined location in the transportation space;

selectably commanding shutdown, via the remote communication link between the vehicle accountant controller and each of the multiple independent automated vehicles, of only the at least one of the multiple independent automated vehicles at the registered location, and not other of the vehicles; and

effecting, with the control system, a human access lockout to at least a portion of the transportation space depending on the commanded shutdown of only the at least one of the multiple independent automated vehicles at the registered location.

16. The method of claim 15, further comprising effecting independent navigation through the transportation space for each of the multiple independent automated vehicles.

17. The method of claim 15, wherein the predetermined location defines a zone in the transportation space segregated from another zone in the transportation space.

18. The method of claim 15, wherein the transportation space is three dimensional space with stacked levels, each level having at least one open deck and aisles for the vehicles to traverse, the aisles communicating with the deck so that the multiple independent automated vehicles enter the aisles from the deck.

19. The method of claim 15, wherein the remote communication link is common to both the system controller and the vehicle accountant controller.

20. The method of claim 15, wherein the remote communication link is a wireless link.

21. The method of claim 15, wherein the vehicle accountant controller uses a black channel communication protocol over the remote communication link to command shutdown of the at least one of the multiple independent automated vehicles.

22. The method of claim 15, further comprising opening communication, with the vehicle accountant controller, between the accountant controller and the selected at least one of the multiple independent automated vehicles over the remote communication link for transmitting the commanded shutdown to the selected at least one of the multiple independent automated vehicles.

23. The method of claim 15, further comprising effecting, with the communication protocol of the commanded shutdown, a secure and verified command on receipt by the selected at least one of the multiple independent automated vehicles.

24. The method of claim 15, further comprising effecting secure and verified shutdown of the selected at least one of the multiple independent automated vehicles upon receipt of and in response to the commanded shutdown, and confirming shutdown to the vehicle accountant controller.

25. The method of claim 15, wherein a communication state between the vehicle accountant controller and each of the multiple independent automated vehicles is normally closed and communication is opened by the vehicle accountant controller to the selected at least one of the multiple independent automated vehicles in connection and substantially coincident with the vehicle accountant controller commanding shutdown to the selected at least one of the multiple independent automated vehicles.

26. The method of claim 25, further comprising closing the communication state upon confirmation of shutdown of the selected at least one of the multiple independent automated vehicles by the vehicle accountant controller.

27. The method of claim 25, wherein a communication state between the vehicle accountant controller and each of the multiple independent automated vehicles is normally closed and communication is opened by the vehicle accountant controller to the selected at least one of the multiple independent automated vehicles in connection and substantially coincident with the vehicle accountant controller commanding activation of the selected at least one of the multiple independent automated vehicles previously shutdown.

28. A method comprising:

providing a transportation space including destinations distributed in the transportation space;

providing multiple independent automated vehicles configured for free roving through the transportation space to and between the destinations so that the multiple independent automated vehicles are dynamically distributed through the transportation space; and

providing a control system communicably connected via a remote communication link to each of the multiple independent automated vehicles and having a system controller that addresses each of the multiple independent automated vehicles to different destinations and a vehicle accountant controller separate and distinct from the system controller, the vehicle accountant controller being connected via the remote communication link to each of the multiple independent automated vehicles;

independently and automatically registers a dynamic location of each of at least one of the multiple independent automated vehicles in response to being provided a predetermined location in the transport space and corresponding to the predetermined location in the transportation space; and

selectably commanding shutdown, via the remote communication link between the vehicle accountant controller and each of the multiple independent automated vehicles, of only the at least one of the multiple independent automated vehicles at the registered location, and not other of the multiple independent automated vehicles;

wherein the commanded shutdown as generated for communication by the vehicle accountant controller and received by the selected at least one of the multiple independent automated vehicles, and the system of the selected at least one of the multiple independent automated vehicles responsive to the commanded shutdown define a secure and verified remote shutdown system in compliance with IEC61508, SIL 3 category criteria.

29. A method comprising:

providing a multilevel structure of an automated storage and retrieval system, the multilevel structure defining a storage array with multiple storage locations and defining a transport space distributed through the array for transporting store units;

providing multiple independent automated vehicles configured for free roving the transport space for transportation of store units to and from storage locations in the storage array;

providing personnel access zones formed in the transport space, each zone having transport space closure for closing the portion of the transport space coincident with each zone to entry of vehicles from outside the zone;

providing a control system including vehicle accountant controller configured to communicate with the multiple independent automated vehicles over a remote communication system;

independently and automatically registering, with the vehicle accountant controller, a dynamic location of the multiple independent automated vehicles;

commanding evacuation of the multiple independent automated vehicles, upon identification of a predetermined zone to be opened for personnel access, from within the predetermined zone and shutting down each un-evacuated vehicle in the zone over the remote communication system with common remote communication links received at the multiple independent automated vehicles for evacuation and shutdown commands; and

effecting, with the control system, a human access lockout to at least a portion of the transportation space depending on the commanded shutdown of the selected at least one of the multiple independent automated vehicles.

30. The method of claim 29, wherein the control system and remote communication system are configured so that shutdown commands are communicated via a black channel of the remote communication system to each un-evacuated vehicle.

31. The method of claim 29, wherein the control system is configured so that presence of each un-evacuated vehicle in the predetermined zone is accounted for automatically independent of vehicle position identification by the control system for task allocation.

32. A method comprising:

providing a multilevel structure defining a storage array with multiple storage locations and defining a transport space distributed through the array for transporting store units;

providing multiple independent automated vehicles configured for free roving the transport space for transportation of store units to and from storage locations in the storage array;

providing personnel access zones formed in the transport space, each zone having transport space closure for closing the portion of the transport space coincident with each zone to entry of vehicles from outside the zone;

providing a control system including a vehicle accountant controller configured to communicate with the multiple independent automated vehicles over a remote communication system;

independently and automatically registering, with the vehicle accountant controller, a dynamic location of the multiple independent automated vehicles and, upon identification of a predetermined zone to be opened for personnel access, commanding evacuation of the multiple independent automated vehicles from within the predetermined zone and shutting down each un-evacuated vehicle in the zone over the remote communication system with common remote communication links received at the multiple independent automated vehicles for evacuation and shutdown commands;

wherein the control system, remote communication system and each vehicle of the multiple vehicles is configured so that shutdown, of each un-evacuated vehicle, in response to the commanded shutdown is secured and verified to satisfy IEC61508, SIL 3 category criteria.